Sanding tool

ABSTRACT

A sanding tool having a handle and a base. The handle has a downwardly depending support having a support bottom. The base has a base bottom, having an inner surface and an outer surface and base walls that vertically flank and extend up from the base bottom. The base walls are attached to the support and the outer surface of the base receives an abrasive material. Each the handle and the base have a flexibility characteristic determined by composition and the flexibility characteristic and composition of the base and the handle are different from each other.

PRIORITY CLAIM

This application is based upon and claims the benefit of priority from U.S. Provisional Patent Application No. 62/964,853 filed on Jan. 23, 2020, the entire contents of which are incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure is directed to hand tools, specifically, to sanding tools.

BACKGROUND OF THE INVENTION

Sanding blocks are used in a variety of endeavors from car modeling to home construction. Prior art sanding tools are not only rigid but have flat, planar sanding surfaces which are primarily only effective at sanding at one angle and on flat surfaces. Challenges arise when there is a need to sand non-linear or non-planar surfaces such as compound curves, outside curves inside curves or areas of shape transition.

Flat bottomed sanding tools can only contact non-linear surfaces with only a small area of its sanding surface. To compensate for this occurrence, a user must take great effort to roll the sanding block over the non-linear surface. It is very difficult to sand two curves at once thus a user of a prior art sanding block must sand up and down in a 45-degree pattern. For instance, a car door panel typically has vertical and/or horizontal curves in it, so to sand the car door panel the prior art sanding block has to be held at a 45-degree angle from the horizontal and then rolled over the curves in a vertical, or up and down motion.

Since many prior art sanding tools are rigid, made of hard foam or hard rubber, etc. there is little to no give to the tool. Also, there is no way to sand horizontally as only a tiny part of the block will contact the panel surface. Using prior art sanding tools will commonly result in the tool removing unintended material. For instance, the flat, hard bottom of the prior art sanding tool will sand the highest part, the peak or the crown of a curve but fail to contact the surfaces leading up to the peak of the curve and, as a result, the peak of the curve will be sanded more than the areas lower than the peak.

Thus, a sanding tool is desired that can simultaneously conform to vertical and horizontal curves. A sanding tool is desired that can simultaneously sand vertical and horizontal curves. A sanding tool is desired that is ergonomic. What is desired is a sanding tool that is flexible and malleable. What is desired is a sanding tool with a handle. What is also desired is a sanding tool that permits a user to exert force on a sanding tool such that pressure is applied on the edges of the sanding tool using one's fingertips.

SUMMARY OF THE INVENTION

An ergonomic and flexible sanding tool is provided that permits sanding of surfaces having multiple curves and levels or heights that are not uniform. The tool has a handle and a base. The handle has a downwardly depending support having a support bottom. The base has a base bottom, having an inner surface and an outer surface and base walls that vertically flank and extend up from the base bottom. The base bottom may be flat or rounded. The base bottom may be disposed a distance from the support bottom while in other embodiments, the two may be disposed a distance from each other. The base walls are attached to the support and the outer surface of the base receives an abrasive material. Each the handle and the base have a flexibility characteristic determined by composition and said flexibility characteristic and composition of the base and the handle are different from each other.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a sanding tool of a first embodiment.

FIG. 2 shows the tool of FIG. 1 shown along lines 2-2.

FIG. 3 shows a sanding tool of a second embodiment with end cap not shown.

FIG. 4 shows the tool of FIG. 3 with an end cap removed.

FIG. 5 shows a sanding tool of a third embodiment with end cap not shown.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2 show a sanding tool 1000 having a handle 100 and a base 200 and an optional end cap 250 disposed at the end of base 200. FIG. 2 shows the tool 1000 as seen through lines 2-2. The handle 100 includes a grip 110, and a support comprising a depending stem 120, which ends at support bottom 140. Support bottom 140 is flanked by arms 130. In certain embodiments, a vacuum channel 300 is disposed in the grip 100. The base 200 has base walls 210, base sides 220 that both vertically flank a base bottom 230 having an inner surface 232 and outer surface 234.

In certain embodiments, the base walls 210 are fixedly attached to the stem 120 of the handle 100 and a portion of the base sides 220 are fixedly attached to the arms 130 providing structural support to the tool 1000. The portions of the base side 220 that are not attached to the arms 130 are unrestricted and are able to flex. In tool 1000, the support bottom 140 is disposed a distance from the inner surface 232 of base bottom 230. The base bottom 230 may be flat in one embodiment. The outer surface 234 is designed to receive an abrasive material such as sandpaper. The abrasive paper may be removably adhered to the outer surface 234 using adhesive, hook and loop or other matter. End caps 250 may be used at the ends of the base 200 to conceal the point of attachment of the handle 100 to the base 200. See FIG. 1.

The handle 100 and base 200 are made of any material that permits give, motion or stretching. In one embodiment, the handle 100 is made of foam and the base 200 is made of rubber such as but not limited to a polyurethane rubber having a density and flexibility characteristic. The handle 100 has a given flexibility characteristic determined by its composition, similarly the base 200 has a flexibility characteristic and composition different from that of the handle. In one embodiment, block 1000 may be suited to convex curved surfaces. In other embodiments, the sanding tool 1000 is malleable to convex and concave surfaces and is able to twist where needed. Thus, unlike with the prior art, the tool 1000 may be used to sand a surface in various directions such as but not limited to horizontally and vertically.

In one embodiment, the malleability of the sanding tool 1000 is achieved by way of the materials used and construction of the sanding tool 1000. The sanding tool 1000 is further malleable due to the portion of the base sides 220 being unattached to the arms 130 and the base bottom 230 being disposed a distance from the support bottom 140. In this arrangement, the sanding tool 1000 is able to flex as the base bottom 230 is not rigid and is able to dip into the space within the tool 1000 between the inner surface 232 of base 200 and the support bottom 140. As a result, the tool 1000 is able to conform to outward compound curves and also accommodate various curves or depressions.

The tool 1000 can be used to sand multi-curved surfaces such as compound curved surface or a rolling twist type curve as seen in many newer vehicles. The sanding tool 1000 is able to sand surfaces such multiple curve surfaces (MCS) due to the malleability of the sanding tool 1000. When tool 1000 is used on an arched or curved surface the base 200 of the sanding tool 1000 conforms, or hugs, the contoured shape of the arched or compound curved surface. Thus, tool 1000 sands and conforms to two curves at once. For instance, when sanding tool 1000 is used with a multiple curve surface (MCS) of a car door, both a horizontal curve as well as a vertical curve are sanded. The tool 1000 simultaneously sands the peak or crown of the multiple curve surface (MCS) as well as the surfaces leading up to the peak or crown. In contrast, prior art typical sanding devices permit sanding in either a vertical, up and down orientation, or a horizontal or lengthwise curve. The prior art sanding device sands the crown or peak, wearing the peak down. It is only once the user shifts the angle of the prior art sanding device does it contacts a surface of a different angle or lower height from the peak on the surface to be sanded.

In one embodiment, tool 1000 has a triangle shaped profile. The handle 100 may be glued to the sides of base 200, such as at base walls 210. This allows a center potion of base 200 such as base bottom 230 to deflect or bend inward as there is space between base bottom 230 and support bottom 140. In some embodiments, tool 1000 may be used for compound curved convex surfaces and is effective when sanding horizontally. For instances when sanding door panels, tool 100 can be used with 45-degree angle motions and vertically as needed and the needs of the panel surface dictates.

FIG. 3 shows a sanding tool 2000 of a second embodiment, having a handle 100 and base 260. End caps 250 are not shown but may be used with the tool 2000. Here the base walls 210 jut out to form base lip 240 or overhang and the base bottom 230 has holes 236. In contrast to tool 1000, the lip 240 provides a feature of being flexible on the edge due to the specific shape. The length of the base lip 240 may extend past the profile of the handle, in other embodiments the base lip 240 may stay within the silhouette of the handle 100. In one embodiment, the lip 240 can deform or stretch/flex over transition areas that go from flat to convex. As a result, block 2000 can flex or bend around curved areas such as a wheel flare or transition from flat to outward curved surfaces.

The handle 100 has extenders such as but not limited to teeth 145 at the support bottom 140. The handle 100 also has a vacuum adapter 310 attached to vacuum channel 300, which then funnels out into vacuum ducts 320 that end at the support bottom 140. The vacuum ducts 320 align with the holes 236 in the base 200. In some embodiments, the base walls 210 are attached to the stem 120 and the teeth 145 abut and are attached to the inner surface 232 of the base bottom 230. In such an arrangement, the attachment points enable tool 2000 to be sturdy.

When the support 120 is attached to the base walls 210, passageways 150 are created. See FIG. 4. When the teeth 145 are attached to the base bottom 230, cross passageway are created between adjacent teeth 145 and the gap created therebetween (not shown), A vacuum network is realized once end caps 250 are installed to create a closed chamber in the tool 2000 and a vacuum is attached to the adapter 300. Specifically, once the vacuum adapter 310 is attached an external vacuum, the passageways 150, cross passageways along with the vacuum channel 310 and vacuum ducts 320 permit the vacuum network to be realized. By attaching a vacuum to the tool 2000, the use is able to enable sand a surface and simultaneously suck dust away. In alternate embodiments, the tool 2000 may be made without holes 236, the vacuum adapter 300 or the vacuum network.

As seen in the figures, tool 2000 may have a semi-triangle shape profile with a flat bottom and overhanging flexible edges, the lip 240, along the length of the base 200. Tool 2000 may be used to sand flat and single curved surfaces into transition areas such as a wheel flare and so on. Tool 2000 can be used on convex or concave surfaces with a 45-degree sanding motion and horizontally if the panel surface is near flat.

FIG. 5 shows sanding tool 3000 having base 280 which has a rounded outer surface 238, End caps 250 are not shown but may be used with the tool 3000. Like with tool 2000, base wall 210 of base 280 may be attached to the sides of stem 120 and the teeth 145 of the handle 110 abut and are attached to the inner surface 232 of base bottom 230. In some embodiments tool. 3000 may have a vacuum adapter 300 and, similar to tool 2000 shown in FIG. 4, will have passageways 150 and cross passageway to create a vacuum network. Tool 3000 may bend to conform to any surface, such as but not limited to concave, convex curves, compound curves, single curved surfaces, double curves, translation and revolution surfaces, twisted curves and reverse curved surfaces.

Tool 3000 may have a triangle-shaped profile with a rounded bottom. Tool 3000 may be used in concave curved areas as well as compound concave areas. Tool 3000 may be used horizontally when a curvature of a workpiece is similar to the curvature of the block bottom 238 and can be used with 45-degree motions when need be.

Similar to sanding tool 1000, sanding tools 2000 and 3000 are able to bend vertically, horizontally and other directions and is twistable. Tool 1000 may be used to sand a convex double curve that is curved horizontally and vertically. The tool 1000 is moved over the surface horizontally and at 45 degrees to the horizontal axis to be able to sand two curves simultaneously.

Sanding tool 1000 and 3000 are malleable and able to sand surfaces having multiple curves. Tool 1000 may be suitable to sand single curved surfaces. Users can sand panels or surfaces right to left instead of at 45 degrees, which is typically associated with sanding using prior art sanders. Accordingly, tool 1000 may speed up sanding work as the user is able to sand in a long direction. The tool 1000 sands only the curve of the surface or panel.

In one embodiment, tool 300 may be made for concave surfaces and compound concave surfaces. On concave single curve surfaces sanding tool 3000 can be used horizontally while tool 2000 can be used vertically. On concave double curve surfaces, also called a compound curve, which are curved horizontally and vertically, tool 3000 can be used to sand horizontally and vertically and in angular motions of 45 degrees from the horizontal position. A single convex curve, having a curve vertically and being flat horizontally, may be sanded using tool 2000 by sanding vertically and horizontally at a 45-degree angle.

The sanding tool 1000, 2000, and 3000 can be made of any length or size and made of any material suitable to achieve flexibility. In another embodiment, the sanding tools 1000, 2000, and 3000 may incorporate a vacuum system within or connects to a vacuum system to suck and capture sanding dust. In yet another embodiment abrasive paper, such as sanding paper, may be integrated with the base bottom 230, 260, 280 and be removably attached to the outer surface 234. Alternatively, the sanding paper may be releasably attached to the base 200, 260, 280 including any foreseeable mechanism such as but not limited to Velcro, clips, glue, releasably removeable sticky material. In one embodiment, the sanding tool 1000, 2000, 3000 may be twelve inches long and three inches wide but other size embodiments are feasible. The sanding tool 1000, 2000, 3000 may be made of a flexible polyurethane material, the base 200 may be made of a flexible rubber bottom. In certain embodiments, the sanding tool 1000, 2000, 3000 may be produced with adhesive, Velcro or clip-on sandpaper.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims. One of ordinary skill in the art could alter the above embodiments or provide insubstantial changes that may be made without departing from the scope of the invention. 

I claim:
 1. A sanding tool comprising: a handle, the handle having a support, the support downwardly depends from the handle, the support having a support bottom, the handle having a given flexibility characteristic determined by its composition; and a base, the base having a base bottom, having an inner surface and an outer surface, and base walls, said base walls vertically flanking the base bottom, the base having a flexibility characteristic and composition different from the flexibility characteristic of the handle, wherein the base walls are attached to said support, wherein the outer surface receives an abrasive material.
 2. The tool of claim 1, wherein the base bottom is disposed a distance from the support bottom.
 3. The tool of claim 2, wherein the base bottom is flat.
 4. The tool of claim 1, further comprising an extender attached to the support bottom, wherein the extender abuts the inner surface of the base bottom.
 5. The tool of claim 4, wherein the base bottom is flat.
 6. The tool of claim 4, wherein the base bottom is rounded.
 7. The tool of claim 1, wherein the handle further comprises a vacuum adapter and a vacuum channel.
 8. The tool of claim 1, wherein the handle and the base are rigid and flexible.
 9. The tool of claim 1, wherein the handle and the base are made of rubber.
 10. A sanding tool comprising: a handle, the handle having a support, the support downwardly depends from the handle, the support having a support bottom, and arms that flank the support bottom, the handle having a given flexibility characteristic determined by its composition; and a base, the base having a base bottom, having an inner surface and an outer surface, and base sides, said base sides vertically flanking the base bottom, and base walls, said base walls vertically extending from the base sides, the base having a flexibility characteristic and composition different from the flexibility characteristic of the handle, wherein the base walls are attached to said support, and portions of the base sides are attached to the arms that flank the support bottom, wherein the base bottom is disposed a distance from the support bottom, wherein the outer surface receives an abrasive material. 